Match Mold for a Hollow Metal Bar Continuous Casting Device

ABSTRACT

The present utility model provides a match mold for a hollow metal bar continuous casting device, including a base and an extension body, which extends perpendicularly with respect to the base, wherein: the base includes an aperture adapted to allow passage of liquid metal into the casting device; and the extension body includes a radial projection adapted to exchange heat with a cooling system of the continuous casting device.

FIELD OF THE UTILITY MODEL

The present utility model is related to molds for obtaining hollow profiles in metal bars through continuous casting processes.

FUNDAMENTALS OF THE UTILITY MODEL

Metal bars are widely used in various areas of industry. In particular, the demand for hollow profile metal bars has grown widely. Such bars may comprise a wide variety of formats, which vary according to the specific application of each case, in particular when produced by a continuous casting process.

For the manufacture of such bars, cast iron molding devices are used, which generally receive cast iron at one end, mold and cool the cast iron, partially solidifying it, and release a cast iron segment into a second end. The described process is continuous, so as to form a continuous bar through this process. The profile of the mold can be varied so as to adapt to each application.

Some state of the art documents are directed to the technology in question and the most relevant ones will be presented below.

Document CN 106001469 discloses a continuous casting process for the manufacture of cast iron profiles. Such document discloses a mold, which generally includes a crystallizer body defining the external dimensions of the molded profile. The crystallizer body is cooled by an external cooling jacket, which allows the circulation of water externally to the crystallizer, thus, the cast iron is inserted into the mold through an inlet end, the interior of the mold is then filled with the cast iron. At that time, the outermost portion of the cast iron inside the mold, which is in contact with the crystallizer, has its temperature reduced rapidly, which causes its partial solidification, ensuring that the formed profile will maintain the shape of the crystallizer after being expelled by an outlet end of the mold. A number of possibilities of graphite crystallizer formats are presented, which makes it possible to manufacture various metal bars. However, in no configuration it is possible to manufacture a bar with a hollow profile, i.e., a completely closed bar with a hollow region in its interior.

Document CN 1056642 discloses a process and a device for the production of cast iron profiles similar to the one written above, wherein the same described elements are adopted in that configuration. Therefore, as in the knowledge disclosed by document CN 106001469, the document in question enables the manufacture of iron bars of varying profiles, but does not enable the manufacture of a bar with hollow profile.

Therefore, from the description of the state of the art, it is clear that it lacks a device for the production of cast iron bars, which enables the manufacture of bars with hollow profiles, which may lead to a shorter machining time in certain applications, such as for example, in the manufacture of wall plug or cylinder liners.

OBJECTIVES OF THE UTILITY MODEL

The purpose of the present utility model is to provide a device for the manufacture of continuous cast metal bars, which allows the manufacture of bars of various shapes with hollow profile without the need for machining processes.

SUMMARY OF THE UTILITY MODEL

In order to achieve the above-described objects, the present utility model provides a match mold for continuous casting device (the continuous casting device is of the type comprising a shell having an inlet end adapted to receive a match mold and an outlet end adapted to release solidified metal, and a cooling system disposed around the shell), which, adapted to be housed within the shell, comprises a base and an extension body that extends axially relative to the base, being that the base comprises an aperture adapted to allow passage of liquid metal into the shell and the extension body comprises a radial projection adapted to develop physical contact with at least a portion of the inner face of the shell, in order to exchange heat with a cooling system.

Preferably, the radial projection of the match mold is positioned in a region diametrically opposite the opening of the base.

Preferably, the match mold base is positioned at the inlet end of the shell, so as to obstruct it.

BRIEF DESCRIPTION OF THE DRAWINGS

The detailed description given below makes reference to the attached Drawings and their respective reference numerals.

FIG. 1 shows a perspective view of an optional configuration of the hollow bar casting device.

FIG. 2 shows a cross-sectional view of the optional configuration of the hollow bar casting device shown in FIG. 1.

FIG. 3 shows a perspective view of a graphite match mold according to an optional embodiment of the present utility model.

FIG. 4 shows an exploded view of the configuration of the hollow bar casting device shown in FIG. 1.

DETAILED DESCRIPTION OF THE UTILITY MODEL

First of all, it is pointed out that the following description will depart from a preferred embodiment of the utility model. As will be apparent to any person skilled in the art, however, the utility model is not limited to that particular embodiment.

FIG. 2 shows a cross-sectional view of a hollow bar casting device according to an optional configuration of the present utility model. The illustrated device comprises a graphite shell (2), which comprises an inlet end (20) adapted to receive a match mold and an outlet end (21) adapted to release solidified metal. In addition, there is also provided an innovative graphite match mold, which extends longitudinally, at least partially, through the interior of the shell (2).

The match mold comprises a base (11) with an aperture (10) adapted to allow passage of liquid metal into the casting device. As can be seen, the base (11) of the match mold is sealingly in contact with the inlet end (20) of the shell (2), so that the passage of liquid metal into the shell is only allowed through the aperture (10) of the base.

Thus, the liquid metal fills the interior of the graphite shell (2) so as to be molded therewith. The contact of the liquid metal with the shell (2) causes the liquid metal to be cooled rapidly, solidifying the outermost portion of the metal and molding a bar segment. In this way, an already cooled and, consequently, shaped bar segment is released by the outlet end (21) of the shell (2). In this manner, the device of the present utility model can be used in a continuous casting process for the production of hollow bars.

FIG. 2 shows a cross-sectional view of the optional configuration of the hollow bar casting device described, wherein it is possible to observe that a cooling system (3) is adopted for the shell (2), so as to intensify the cooling of the liquid metal layer in contact with the shell (2), accelerating its solidification. Thus, the bar segments are more quickly formed.

In the configuration illustrated, the cooling system (3) of the shell (2) is based on the circulation of a cooling fluid, optionally water, by a cooling jacket (3) surrounding the shell (2). The jacket comprises a fluid inlet channel (33) and a fluid outlet channel (34), wherein the fluid is inserted through the inlet channel (33), moved by channels (35) to flow through the entire area of the cooling jacket (3) and finally drawn out by the outlet channel (34). Many cooling systems are known from the state of the art, so that the utility model provides for the use of any known system for cooling the shell (2). A person skilled in the art will be able to determine the best system to be adopted, according to specific needs of each application.

FIG. 3 shows an isolated view of a graphite match mold according to an optional configuration of the present utility model. This member is similar to the match mold shown in FIGS. 1 and 2.

In this figure, it becomes clearer that the graphite match mold of the present utility model comprises a base (11) and an extension body (1), which extends axially relative to the base (11). In addition, the base (11) comprises an aperture (10) adapted to allow passage of liquid metal into the casting device.

It is also noted that the extension body (1) of the match mold comprises a radial projection (12) adapted to exchange heat with a cooling system (3) of the continuous casting device.

As previously described, when in use, the base (11) of the match mold is in contact with the entire contour of the inlet end (20) of the graphite shell (2), so that the contact is sealing. In this way, the only possible passage of the liquid metal into the shell (2) is through the aperture (10) of the match mold base (11).

In addition, it is also more clearly observed that the extension body (1) of the match mold comprises a radial projection (12) in a region just posterior to the base (11), wherein the radial projection (12) comes into contact with an inner wall of the shell (2). In order that the radial projection (12) does not prevent the entry of liquid metal into the shell (2), it may be positioned in a region diametrically opposite the aperture (10) of the base (11).

The contact of the radial projection (12) with the inner wall of the shell (2) allows the match mold to exchange heat by conduction with the shell (2), cooling the match mold. This cooling has the main purpose of aiding the solidification of the liquid metal in contact with the match mold. Thus, upon solidification of the metal in contact with the match mold, the formed bar comprises a hollow space with the shape and dimensions of the graphite match mold. The cooling of the match mold, provided by the radial projection (12), is fundamental so that the match mold maintains its physical properties, avoiding that it is heated to the temperature of the liquid metal. This prevents it from being seriously damaged, which would cause the casting process to be interrupted or even serious accidents with the operators.

Again, with respect to FIG. 2, it is noted that the shell (2) and the extension body (1) of the match mold delimit a molding chamber, which gives the final shape to the molten metal bar segment, wherein the match mold is responsible for the hollow profile of such bar segment.

Therefore, in use of the continuous casting device match mold, the liquid metal is thus inserted into the shell (2) through the aperture (10) in the base (11) of the match mold, and the liquid metal then fills the space between the match mold and the inner wall of the shell (2) (molding chamber). As the shell (2) and the match mold comprise a temperature well below the temperature of the liquid metal, the contact of the liquid metal with these elements causes the metal to solidify in that region, forming a hollow bar segment with the external dimensions of the shell (2) and the internal dimensions of the extension body (1) of the match mold.

Optionally, the outer wall of the match mold is parallel to the inner wall of the shell (2). In this way, the formed bar would comprise the same internal (hollow) cross-sectional shape and externally. However, in specific applications, the shape of the shell (2) and the match mold may be different.

Optionally, both the shell (2) and the extension body (1) of the match mold comprise a tubular/cylindrical shape.

Also optionally, the match mold comprises a length greater than the length of the shell (2), so that the match mold is longer than the shell (2) and extends beyond the outlet end (21) of the shell (2). This configuration may be required due to the fact that the match mold has a less efficient cooling than the shell (2). Thus, in order for the metal in contact with the match mold to be completely solidified, a longer contact time with the match mold may be required, compared to the shell (2).

If the adopted configuration also comprises the cooling system (3) of the shell (2), the process described above will be faster and more efficient. In addition, more efficient cooling of the shell (2) will also provide for more efficient cooling of the graphite match mold.

It is noted that the cooling of the graphite elements, shell (2) and match mold also represents a structural advantage, since it prevents graphite being raised to very high temperatures, which would represent a serious risk of breaking of these elements, in particular the match mold.

Optionally, the end of the match mold opposite the base (11) comprises a gradual reduction (13) of the cross-sectional area to avoid termination with sharp edges, which could result in the breaking of small fragments of the match mold, or even of that entire element.

To assist in the extraction of the metal bar segments formed within the device, a traction system exerting a pulling force on the bar segment formed within the shell (2) can be adopted.

FIG. 4 shows an exploded view of the configuration of the hollow bar casting device shown in FIG. 1. In this figure it can be seen that the cooling jacket (3) comprises an inner jacket (31) and an outer jacket (32), secured with aid stoppers (4). The inner jacket (31) is in contact with the shell (2) and is responsible for exchanging heat with (cooling) the same.

It is also noted that, in the illustrated configuration, the inner jacket (31) of the cooling jacket (3) comprises fins forming guide channels (35) for the outflow of water. These guide channels (35) may have the desired configuration according to the application.

Therefore, it is clear that the hollow metallic bar continuous casting device match mold described makes it possible to manufacture hollow bars in a very efficient and finely finished manner, which cannot be achieved by the technology known from the state of the art.

In particular, the proposed graphite match mold comprises a configuration, which provides effective cooling during the casting process of metal bars. This feature provides a high finish in the casting of the internal bore of the bar produced, which is not achieved by any device of this type, known from the state of the art.

Numerous variations relating to the scope of protection of the present application are permitted. In this way, the fact that the present utility model is not limited to the particular configurations/embodiments described above is reinforced. 

1. Match mold for continuous casting device, said continuous casting device being of the type comprising a shell provided with an inlet end adapted to receive a match mold and an outlet end adapted to release solidified metal; and a cooling system arranged around the shell; said match mold for continuous casting device is adapted to be housed inside the shell, and is especially characterized in that it comprises: a base and an extension body that extends axially relative to the base; the base comprises an aperture adapted to allow passage of liquid metal into the shell; the extension body comprises a radial projection adapted to develop physical contact with at least a portion of the inner face of the shell in order to exchange heat with a cooling system.
 2. Match mold, according to claim 1, characterized in that the radial projection is positioned in a region diametrically opposite the opening of the base.
 3. Match mold, according to claim 1, characterized in that the base is positioned at the inlet end of the shell so as to obstruct it. 